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转炉炉衬侵蚀机制及烧穿预警技术研究进展

Research progress on erosion mechanism and burn-through early warning technology of converter lining

  • 摘要: 转炉炉衬是保障炼钢过程安全稳定运行的关键结构,其服役状态直接影响转炉炉龄、耐火材料消耗量及生产安全。在周期性装料、吹炼和出钢过程中,炉衬长期受到高温熔渣与钢液作用、机械冲击与冲刷、温度循环以及结构约束等多因素耦合影响,局部区域容易发生异常侵蚀、开裂和剥落,严重时可引发烧穿与漏钢事故。本文系统综述了转炉炉衬侵蚀机制、侵蚀状态监测及烧穿预警技术的研究进展。首先,从化学侵蚀与熔渣渗透、机械冲击与磨损、热震损伤及结构应力等方面归纳了转炉炉衬的主要损毁机制,并分析了渣线区、耳轴区、出钢口、炉底和加料侧等典型部位侵蚀行为的区域性与阶段性特征;其次,总结了冶炼温度与时间、炉渣MgO含量、全铁含量、炉渣碱度、装料制度及吹炼操作等因素对炉衬侵蚀的影响。在此基础上,重点评述了红外热成像、激光测厚、电学检测、声学检测、神经网络预测及多源信息融合等炉衬状态监测与烧穿预警方法的基本原理、技术特点和工程应用现状。现有研究表明,红外热成像适用于炉壳热点的在线连续监测,激光测厚能够定量表征炉衬残余厚度及局部薄弱区域,而电学、声学和多源信息融合方法在连续感知及提高预警可靠性方面具有一定应用潜力。然而,复杂现场环境、监测数据时空不连续、模型跨炉役适用性不足以及预警阈值缺乏统一标准等问题,仍制约着相关技术的推广应用。未来应加强炉衬侵蚀机制与数据驱动模型的深度融合,推动多源监测信息协同、残余厚度与侵蚀速率联合表征以及分区域、分等级动态预警体系建设,为转炉炉衬预知性维护和安全长寿运行提供支撑。

     

    Abstract: Converter lining is regarded as a critical structure for guaranteeing safe and stable operation of steelmaking processes. Its service state is directly reflected in converter campaign life, refractory consumption and production safety. During cyclic charging, blowing and tapping operations, the lining is subjected to coupled influences of multiple factors including attack by high-temperature molten slag and liquid steel, mechanical impact and scouring, thermal cycling and structural constraints. Abnormal erosion, cracking and spalling are easily induced in local zones, and burn-through and steel breakout accidents can be triggered under severe conditions. Systematic reviews are conducted on research progress concerning erosion mechanisms, erosion state monitoring and burn-through early warning technologies for converter linings. First, major damage mechanisms of converter linings are summarized from the perspectives of chemical erosion and slag penetration, mechanical impact and abrasion, thermal shock damage and structural stress. Regional and staged characteristics of erosion behaviours in typical zones are analysed, including the slag line zone, trunnion zone, tapping spout, furnace bottom and charging side. Second, influences of multiple factors on lining erosion are elaborated, such as smelting temperature and duration, MgO content, total iron content and basicity of slag, charging schedule and blowing operations. On this basis, fundamental principles, technical characteristics and engineering application status of lining condition monitoring and burn-through early warning approaches are emphatically reviewed, covering infrared thermography, laser thickness measurement, electrical detection, acoustic detection, neural network prediction and multi-source information fusion. Findings from existing investigations indicate that infrared thermography is adopted for continuous on-line monitoring of hot spots on the furnace shell. Laser thickness measurement is employed to quantitatively characterise residual lining thickness and local weak zones. Certain application potentials are demonstrated by electrical detection, acoustic detection and multi-source information fusion methods in continuous perception and improvement of early warning reliability. Nevertheless, popularisation and application of relevant technologies are still restricted by problems such as complicated on-site environments, temporally and spatially discontinuous monitoring data, insufficient cross-campaign adaptability of models and the absence of unified criteria for early warning thresholds. In future, deep integration between lining erosion mechanisms and data-driven models should be strengthened. Promotions should be realised for coordination of multi-source monitoring information, joint characterisation of residual thickness and erosion rate, and construction of a zoned and graded dynamic early warning system. Supports can thereby be provided for predictive maintenance and safe long-service operation of converter linings.

     

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